Adjustable handheld sander

ABSTRACT

An adjustable sander having a body and a flexible base. The flexible base includes a first end and a second end spaced apart from one another. The first end and second end are each pivotally attached to the body. The flexible base is configured to move between a concave configuration, a neutral configuration, and a convex configuration relative to the body. The adjustable sander further includes a removable sanding surface affixed to a surface of the flexible base that is distal from the body. The adjustable sander also includes a locking mechanism configured to selectively hold the flexible base in a desired concave, neutral or convex configuration. The locking mechanism is characterized in that it includes an axial having a head and a shaft having a series of shaft notches.

This patent application claims priority to EP Application 21201454.2 filed Oct. 7, 2021 which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a sander. More particularly, the present invention relates to an adjustable sander that is suitable for use on both flat and curved surfaces.

SUMMARY OF THE INVENTION

Sanders are well known tools. They are typically used in automotive or manufacturing applications wherein there is a need to obtain a smooth surface. Sanding is often applied to flat substrates. A handheld sander having a flat sanding surface may easily sand such flat substrates. However, often times there is a need to sand an object with a curved substrate. In such instances, a sander with a flat sanding surface may prove to be inadequate and even burdensome.

To address this problem, it is known to have a sander with a flexible base and sanding surface. The sanding surfaces of such sanders may contour to the substrate that is being sanded. However, such sanders require the operator to apply constant and even pressure so that the flexible sanding surface remains in contact with the curves of substrate. It would be advantageous to have a sander that is adjustable wherein the operator can select the contour (convexity or concavity) of the base and have said contour position maintained without further effort from the operator.

The present invention addresses one or more of the aforementioned problems by problems by providing an adjustable sander having a body and a flexible base. The flexible base includes a first end and a second end spaced apart from one another. The first end and second end are each pivotally attached to the body. The flexible base is configured to move between a concave configuration, a neutral configuration, and a convex configuration relative to the body. The adjustable sander further includes a removable sanding surface affixed to a surface of the flexible base that is distal from the body. The adjustable sander also includes a locking mechanism configured to selectively hold the flexible base in a desired concave, neutral or convex configuration. The locking mechanism is characterized in that it includes an axial having a head and a shaft having a series of shaft notches. The locking mechanism further includes a selector having an operator surface and a holder. The operator surface is accessible from outside the body. The holder includes an engagement surface having at least one holder notch configured to selectively engage at least one of the shaft notches. The selector is selectively movable between an engaged position wherein the at least one holder notch is engaged to one of the shaft notches, and a disengaged position, wherein the at least one holder notch is disengaged from the shaft notches.

The terminology used herein is for the purpose of describing implementations or embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms, “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the root terms “can”, “include”, “can include”, “may”, and/or “have”, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of at least one other feature, step, operation, element, component, and/or groups thereof.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus.

As used herein “substantially,” “generally,” “slightly” and other words of degree are relative modifiers intended to indicate permissible variation from the characteristic so modified. It is not intended to be limited to the absolute value or characteristic which it modifies but rather possessing more of the physical or functional characteristic than its opposite, and preferably, approaching or approximating such a physical or functional characteristic.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following descriptions of embodiments of the invention taken in conjunction with the accompanying drawings:

FIG. 1 is a perspective view of a first embodiment of the adjustable sander.

FIG. 2 is a cutaway view of the first embodiment along a first axis.

FIG. 3 is a cutaway view of the first embodiment along a second axis.

FIG. 3 a is a detailed view of an inset of FIG. 3 .

FIG. 4 a is a perspective view of the locking mechanism of the first embodiment.

FIG. 4 b is a perspective view of the locking mechanism of the first embodiment with the sleeve and detent housing removed.

FIG. 5 is and exploded view of the first embodiment.

FIG. 6 is a perspective view of a second embodiment of the adjustable sander.

FIG. 7 is a cutaway view of the second embodiment along a first axis.

FIG. 8 is a cutaway view of the second embodiment along a second axis.

FIG. 9 a is a perspective view of the locking mechanism of the second embodiment.

FIG. 9 b is a perspective view of the locking mechanism of the second embodiment with the sleeve removed.

FIG. 10 is an exploded view of the second embodiment.

FIG. 11 is a perspective view of a third embodiment of the sander.

FIG. 12 is a cutaway view of the third embodiment along a first axis.

FIG. 13 is a cutaway view of the third embodiment along a second axis.

FIG. 14 a is a perspective view of the locking mechanism of the third embodiment.

FIG. 14 b is a perspective view of the locking mechanism of the third embodiment with the sleeve removed.

FIG. 15 is an exploded view of the third embodiment.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-5 show an adjustable sander 10 in accordance with a first embodiment of the present invention. The adjustable sander 10 includes a body 12 and a flexible base 14. The body 12 may be a single housing or it may be of a two-part clam shell design. The flexible base 14 has a first end 16 and a second end 18 spaced apart from one another. The first end 16 and second end 18 is each pivotally attached to the body 12, and wherein the flexible base 14 is configured to move between a concave configuration, a neutral configuration, and a convex configuration relative to the body 12. The adjustable sander 10 also includes a removable sanding surface 20 affixed to a surface of the flexible base 14 that is distal from the body 12. The adjustable sander 10 also includes a locking mechanism 22 that is configured to selectively hold the flexible base 14 in a desired concave, neutral or convex configuration.

The locking mechanism 22 includes an axial 24. The axial includes a head 26 and a shaft 28, having a series of shaft notches 30. The shaft notches 30 may be positioned on a single side of the shaft 28; on multiple sides of the shaft 28; or may be a screw-like surface that encompasses a circumference of the shaft 28. In alternate embodiments, the locking mechanism 22 may further include a sleeve 32 that is positioned around the shaft 28. Also included in the locking mechanism is a selector 34. As shown in FIG. 1 , the selector 34 may be a thumb slider 78. Alternatively, as shown in FIG. 6 , the selector 34 may be winged slider 80. The selector 34 includes an operator surface 38 and a holder 38. Those skilled in the art will recognize that the selector 34 and holder 38 may be a single integrated piece or it may be multiple interconnected pieces. The operator surface 36 is accessible from outside the body 12 and the holder 38 includes an engagement surface 40 having at least one holder notch 42 that is configured to selectively engage at least one of the shaft notches 30. The selector 34 is movable between an engaged position wherein the at least one holder notch 42 is engaged to one of the shaft notches 30, and a disengaged position, wherein the at least one holder notch 42 is disengaged from the shaft notches 30. In the first embodiment, the holder 38 is substantially U-shaped 44. It includes two tines 46 each having an engagement surface 40 with at least one holder notch 42 thereon. The two tines 46 of the holder 38 are spaced apart such that they can accommodate the shaft 28 therebetween.

In a preferred embodiment, the sleeve 32 of the locking mechanism 22 may further define a window 58. The engagement surface 40 of the holder 38 may engage the shaft notches 30 through said window 58. The sleeve 32 may also include one or more holder guides 110. In this first embodiment, the holder guides 110 may be positioned immediately adjacent window 34. As best shown in FIG. 4 a , the holder guides 110 are configured to receive and guide the tines 46 into their engagement position. The holder 38 is configured move horizontally between its engagement and disengagement positions. As the holder 38 is moved into its engagement position, the holder guides 110 may also prevent perpendicular axial movement of holder 38. Thus, the holder guides 110 may assist in securing the selector in its engaged position. Those skilled in the art will recognize that the sleeve 32 may define a second window 62 and include another set of holder guides (not shown) positioned respectively on the sleeve 32 opposite the first window 58 and holder guide 110.

The locking mechanism may further include a detent 82 that is biased by a spring 84. The detent 82 and spring 84 are configured to prevent unwanted movement of the selector 34. In a preferred embodiment, the detent 82 and spring 84 are positioned inside the body 12. In a preferable embodiment, the detent 82 and detent spring 84, may be positioned within a detent housing 85 within the body 12. The spring 84 biases the detent 82 toward the holder 38. The detent 82 is configured to engage detent receiving surfaces 86, which are defined by the holder 38. As the selector 34 is moved between the engaged position and the disengaged position, the detent 82 is biased by the spring 84 toward the detent receiving surface 86. Once engaged to the detent receiving surface, the spring biased detent holds the selector 34 in the desired position, thereby preventing unwanted movement. When the operator desires to move the selector 34 to its other position, she must apply enough force so that the detent 82 presses back against the spring 84. When the selector reaches its desired position, the spring 84 biases the detent 82 into another detent receiving surface 86.

In a preferred embodiment, the locking mechanism 22 further includes a spring 88 positioned around the shaft 28. Spring 88 is configured to be selectively compressed between the head 26 of the shaft 28 and the sleeve 32. More specifically, that spring 88 may be selectively compressed between the head 26 of the shaft 28 and wings 33 on the sleeve 32. In operation, spring 88 may bias the flexible base 14 from a convex configuration towards a neutral configuration.

FIGS. 6-10 disclose a second embodiment of the adjustable sander 10. In this embodiment, the locking mechanism 22 differs in that the operator surface 36 of the selector 34 is a winged slider 80. Additionally, in this second embodiment, the holder 38 is a plate 48. Plate 48 defines an opening 50 having a large end 52 and a small end 54. The opening 50 is sized and configured to accommodate the shaft 28 therethrough. The large end 52 of the opening 50 is much larger than the shaft 28 such that an internal edge 56 of the opening 50 cannot engage the shaft notches 30. Conversely, the small end 54 of the opening 50 is only slightly larger than the shaft 28 such that the internal edge 56 of the opening 50, which functions as the holder notch 42 can engage the shaft notches 30. In a preferable embodiment, the shaft 28 includes two sets of shaft notches 30. The internal edge 56 of the opening 50 on the small end 54 is configured to engage both sets of shaft notches 30.

FIGS. 11-15 disclose a third embodiment of the adjustable sander 10. In this embodiment, the locking mechanism 22 includes a gear nut 64 fixed within the body 12. The gear nut 64 includes an interior surface 66 having a series of nut notches 68 thereon. The holder 38 in this embodiment is a gear pin 70. The gear pin 70 includes a first portion 72 having a series of holder notches 44. The gear pin 70 further includes a second portion 74 having a series of locking notches 76 that are configured to selectively engage the nut notches 68 such that when the holder 38 is in the engaged position, the nut notches 68 and the locking notches 76 are engaged to one another. Conversely, when the holder 38 is in the disengaged position, the nut notches 68 and the locking notches 76 are disengaged from one another.

In any of the previously described embodiments, one or more of the following features may also be included. For example, one or the other of the shaft notches 30 and holder notches 44 may be chamfered 45. Still further, both the shaft notches 30 and the holder notches 44 may be chamfered 45. Similarly, in the embodiment wherein the locking mechanism 22 includes a gear nut 64 and a gear pin 70, one or more of the nut notches 68 and locking notches 76 may be chamfered 45. The chamfers 45 in any of said embodiments are configured to ease the sliding engagements between the shaft notches and the holder notches 44 or between the nut notches 68 and the locking notches 76.

Another feature that may be used in any of the previously described embodiments is the body 12 being constructed for a two-part clam shell 90. Such a construction eases the manufacturability of the adjustable sander 10.

Yet another feature that may be used in conjunction with any of the previously described embodiments is the inclusion of first and second connecting arms 92, 94. The first and second connecting arms are spaced apart from one another. Each having one end 96, 98 that is pivotally connected to the flexible base 14, and a second end 100, 102 that is pivotally connected to the body 12. The connecting arms 92, 94 are configured to facilitate greater pivotal movement of the flexible base 14 relative to the body 12.

Another feature that may be used in conjunction with any previously described embodiment is a vacuum tube coupling 104 having a first end 106 and a second end 108. The first end 106 is configured to engage a vacuum mechanism. The second end 108 is configured to facilitate access to sanded particle that are freed by the sanding surface. In operation, the vacuum tube coupling allows for the removal of excess dust from the sanded surface.

While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes and equivalents will occur to those skilled in the art. It is to be understood that the appended claims are intended to cover all such modifications and changes as fall within the scope of the implementations. It should be understood that they have been presented by illustration only, not limitation, and various changes in form and details may be made. Any portion of the apparatus and/or methods described may be combined in any combination. The implementations described can include various combinations and/or sub-combinations of the functions, components and/or features of the different implementations described. 

What is claimed is:
 1. An adjustable sander comprising: a body; a flexible base having a first end and a second end spaced apart from one another, and wherein the first end and second end is each pivotally attached to the body, and wherein the flexible base is configured to move between a concave configuration, a neutral configuration, and a convex configuration relative to the body; a removable sanding surface affixed to a surface of the flexible base that is distal from the body; a locking mechanism configured to selectively hold the flexible base in a desired concave, neutral or convex configuration; and characterized in that the locking mechanism comprises: an axial including a head and a shaft, and wherein the shaft includes a series of shaft notches; a sleeve configured to be positioned around the shaft; a selector having an operator surface and a holder coupled to the selector, wherein the operator surface is accessible from outside the body and the holder includes an engagement surface having at least one holder notch configured to selectively engage at least one of the shaft notches, and wherein said selector is selectively movable between an engaged position wherein the at least one holder notch is engaged to one of the shaft notches, and a disengaged position, wherein the at least one holder notch is disengaged from the shaft notches.
 2. The adjustable sander of claim 1, wherein the holder is U-shaped and includes two tines each having an engagement surface with at least one holder notch thereon.
 3. The adjustable sander of claim 1, wherein holder is a plate defining an opening having a large end and a small end, and wherein at the large end, the opening is much larger than the shaft such that an internal edge of the opening, which functions as the holder notch, cannot engage the shaft notches, and wherein at the small end, the opening is only slightly larger than the shaft such that the internal edge of the opening, which functions as the holder notch can engage the shaft notches.
 4. The adjustable sander of claim 1, wherein the sleeve further defines a window, and wherein the engagement surface of the holder may engage the shaft notches through said window.
 5. The adjustable sander of claim 1, wherein the shaft includes a second series of shaft notches and the sleeve further defines a second window.
 6. The adjustable sander of claim 1, wherein the locking mechanism further includes a gear nut fixed within the body and having an interior surface including series of nut notches, and the holder is a gear pin having a first portion including a series of holder notches and a second portion having a series of locking notches configured to selectively engage the nut notches such that when the holder is in the engaged position, the nut notches and locking notches are engaged to one another, and in the disengaged position, the nut notches and locking notches are disengaged from one another.
 7. The adjustable sander of claim 6, wherein at least one of the nut notches and locking notches are chamfered.
 8. The adjustable sander of claim 1, wherein the operator surface of the selector is a thumb slider.
 9. The adjustable sander of claim from 1, wherein the operator surface of the selector is a winged slider.
 10. The adjustable sander of claim 1, wherein the locking mechanism further includes a detent biased by a spring, and wherein said detent is configured to engage detent receiving surfaces on the selector.
 11. The adjustable sander of claim 10, wherein at least one of the shaft notches and holding notches are chamfered.
 12. The adjustable sander of claim 11, further including a spring positioned around the shaft and configured to be selectively compressed between the head of the shaft and the sleeve.
 13. The adjustable sander of claim 1, wherein the body is constructed of a two-part clam shell.
 14. The adjustable sander of claim 1, further including first and second connecting arms spaced apart from one another and each having one end connected to the flexible base, and a second end connected to the body, and wherein said connecting arms are configured to facilitate greater pivotal movement of the flexible base relative to the body.
 15. The adjustable sander of claim 1, further including a vacuum tube coupling having one end configured to engage a vacuum mechanism and the other end configured to facilitate access to sanded particles freed by the sanding surface. 